Packaging having protective materials incorporated therein

ABSTRACT

A packaging article for protectively storing perishable paper products that includes protective materials that protect the packaging article and its contents from any of a number of threats including water damage, fire damage, mold, insects, bacteria, fungi and theft. The packaging article comprises a bottom wall, side walls and a closure that surround and define an interior cavity in which the paper products are stored or transported. Each of the bottom wall, side walls and closure are made from a plurality of layers. Protective materials are applied to one or more of the bottom wall, side walls and closures by either impregnating a paper or cardboard with a suitable chemical, applying a film thereover, spraying a coating thereover or sandwiching the protective material between two adjacent layers. Suitable chemicals that produce the desired properties include, but are not limited to wax, oil, plastic, polybrominated diphenyl ether, polybrominated biphenyl, brominated cyclohydrocarbons, boric acid and hydrogen peroxide. A radio frequency identification tag may also be received within the wall of the packaging article to protect the same against theft.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/703,966, filed Feb. 8, 2007, the entire specification ofwhich is incorporated herein by reference.

BACKGROUND OF THE INVENTION TECHNICAL FIELD

This invention generally relates to storage and transportationmaterials. More particularly, the invention relates to mailing andstorage boxes and envelopes. Specifically, the invention relates toboxes and envelopes that are made of a plurality of different layersthat have protective materials incorporated therein or applied theretoto protect the article from a variety of different threats.

BACKGROUND INFORMATION

Offices and individuals frequently need to store materials such as filesand papers for long periods of time. Typically, these materials areplaced in some sort of storage box for safekeeping. These boxes may takea variety of forms including plastic tubs or corrugated cardboard boxeswith lids. Plastic tubs are convenient and protect the materials storedtherein from dangers such as liquid exposure, but can be relativelyexpensive if large volumes of materials need to be stored. Cardboardboxes on the other hand are inexpensive and convenient, but they arevulnerable to dangers such as water damage, fire, insects and mold.

There is therefore a need in the art for an improved corrugatedcardboard box that is less vulnerable to threats that may damage thecontents of the box.

SUMMARY OF THE INVENTION

The device of the present invention comprises a packaging article forprotectively storing perishable paper products that includes protectivematerials that protect the packaging article and its contents from anyof a number of threats including water damage, fire damage, mold,insects, bacteria, fungi and theft. The packaging article comprises abottom wall, side walls and a closure that surround and define aninterior cavity in which the paper products are stored or transported.Each of the bottom wall, side walls and closure are made from aplurality of layers. Protective materials are applied to one or more ofthe bottom wall, side walls and closures by impregnating a paper orcardboard layer with a suitable chemical, applying a film thereover,spraying a coating thereover or sandwiching the protective materialbetween two adjacent layers. Suitable chemicals that produce the desiredproperties include, but are not limited to wax, oil, plastic,polybrominated diphenyl ether, polybrominated biphenyl, brominatedcyclohydrocarbons, boric acid and hydrogen peroxide. A radio frequencyidentification tag may also be received within the wall of the packagingarticle to protect the same against theft.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention, illustrative of the bestmode in which applicant has contemplated applying the principles, areset forth in the following description and are shown in the drawings andare particularly and distinctly pointed out and set forth in theappended claims.

FIG. 1 is a perspective view of a corrugated cardboard box known in theprior art;

FIG. 2 is a cross-sectional top view through line 2-2 of FIG. 1;

FIG. 3 is a perspective view of a corrugated cardboard box in accordancewith the present invention;

FIG. 4 is a cross-sectional top view of a first embodiment of a sidewall taken through line 4-4 of FIG. 3;

FIG. 4A is a cross-sectional, top view of a second embodiment of theside wall of the storage box of FIG. 3;

FIG. 4B is a cross-sectional top view of a third embodiment of the sidewall of the storage box of FIG. 3;

FIG. 4C is a cross-sectional top view of a fourth embodiment of the sidewall of the storage box of FIG. 3;

FIG. 5 is a cross-sectional top view of a fifth embodiment of the sidewall of the storage box of FIG. 3;

FIG. 6 is a cross-sectional top view of a sixth embodiment of the sidewall of the storage box of FIG. 3 and showing the incorporation thereinof a security tag;

FIG. 7 is a perspective view of a mailing envelope in accordance withthe present invention;

FIG. 8 is a cross-sectional top view of the mailing envelope takenthrough line 8-8 of FIG. 7 and showing the structure of the front wallof the envelope;

FIG. 8A is a cross-sectional top view of a second embodiment of thefront wall of the envelope;

FIG. 8B is a cross-sectional top view of a third embodiment of the frontwall of the envelope; and

FIG. 9 is a cross-sectional top view of a fourth embodiment of the frontwall of the envelope showing the incorporation therein of a securitytag.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show a corrugated cardboard box 10 known in the prior art.Box 10 has a bottom wall (not shown) and four side walls 12 that definean interior cavity 14 for holding a plurality of files or papers 16. Alid 18 is provided for closing off access to cavity 14. Lid 18 may takeany one of a number of different forms, such as four panels as shown inFIG. 1, or a single panel (not shown) or a completely separate lid unit(not shown). The bottom wall, side walls 12 and lid 18 are all made fromcorrugated cardboard. As shown in FIG. 2, the side wall 12 comprises twoplanar sheets 20, 22 which sandwich a corrugated cardboard sheet 24thereinbetween. The cardboard used in box 10 is vulnerable to waterdamage, fire damage, may permit mold to grow thereon if it is subjectedto high moisture environments and is susceptible to paper-eating insetssuch as silverfish and the like.

FIGS. 3-5 show a storage box in accordance with the present inventionand generally indicated at 50. Box 50 is similarly formed to box 10 inthat it has a bottom wall (not shown), side walls 52 that surround anddefine an interior cavity 54 for holding a plurality of files or papers56 therein. A lid 58 is provided for closing off access to cavity 54.Lid 58 shown in FIG. 3 comprises four panels that are secured togetherwith an adhesive tape of the like. It will be understood by thoseskilled in the art that the shape, size and configuration of box 50, asshown in the attached drawings, is by way of illustration only. Anyshape, size and configuration of the box and lid may be used withoutdeparting from the spirit of the present invention.

In accordance with a specific feature of the present invention, each ofthe bottom wall, side walls 52 and lid 58 of box 50 are manufacturedfrom a corrugated cardboard that has been specially treated with one ormore of several protective materials as will are hereinafter described.

Referring to FIG. 4, there is shown a portion of side wall 52 comprisinga first and a second planar sheet 60, 62 of cardboard which sandwich acorrugated sheet 64 of cardboard thereinbetween. It will be understoodby those skilled in the art, that the bottom wall, side walls 52 and lid58 of box 50 may be made up from any number of a plurality of planar andcorrugated sheets that are layered and bonded together to form a unitarymember of the required strength, without departing from the spirit ofthe present invention. The following illustrations show a box wall 52made from two planar sheets and one corrugated sheet for the sake ofclarity only. FIG. 4 illustrates a first embodiment of the side wall 52in which one or more of sheets 60, 62 and 64 are impregnated with aprotective material as will be hereinafter described.

FIG. 4A shows a second embodiment of side wall 152 that includes layerof protective material 166 therein. In this instance, layer 166 isapplied over second sheet 162 and, because second sheet 162 forms theexterior surface of side wail 152, protective layer 166 forms theexternal surface of the storage box.

Referring to FIG. 4B, there is shown a third embodiment of a side wallof the box, being generally indicated at 252. Side wall 252 comprisesfirst and second planar sheets 260, 262 of cardboard which sandwich acorrugated layer 264 thereinbetween. Protective layer 266 is appliedover first sheet 260 and thus forms the interior surface of the box inaccordance with the present invention.

Referring to FIG. 4C, there is shown a fourth embodiment of a side wallfor the box, being generally indicated at 352. Side wall 352 comprisesfirst and second planar sheets 360, 362 of cardboard which sandwich acorrugated layer 364 thereinbetween. A first protective layer 366 isapplied over sheet 362 and a second protective layer 368 is applied oversheet 360. The protective layers 366, 368 therefore form both theexterior and interior surfaces of the box.

Referring to FIG. 5, there is shown a fifth embodiment of a side wallfor the box, being generally indicated at 452. Side wall 452 comprisesfirst and second planar sheets 460, 462 of cardboard which sandwich acorrugated layer 464 thereinbetween. A protective layer 466 is appliedover second sheet 462 and another planar sheet of cardboard 470 isapplied over protective layer 466. Thus, protective layer 466 issandwiched between two layers of untreated cardboard.

Referring to FIG. 6, there is shown a sixth embodiment of a side wallfor the storage box, being generally Indicated at 552. Side wall 552comprises first and second planar sheets 560, 562 of cardboard whichsandwich a corrugated layer 564 thereinbetween. A protective layer 566is applied over second sheet 562. In accordance with another specificfeature of the present invention, side wall 552 further incorporates anRFID (Radio Frequency Identification) tag 580. Tag 580 is sandwichedbetween corrugated layer 564 and planar sheet 562. Tag 580 may be usedto rapidly locate a particular storage box. Tag 580 may also be used asa security device to set off an entryway alarm if the box is removedfrom a storage facility by unauthorized personnel. In this way, tag 580is incorporated as a protective material against the threat of theft.

In accordance with one of the specific features of the presentinvention, one or more layers of the bottom wall, side walls 52 and lid58 of box 50 include protective materials that impart improvedprotective properties to the storage box 50. In a first instance, shownin FIG. 4, any or all of sheets 60, 62 and 64 may be impregnated with aprotective material. Thus, any and all of sheets 60, 62 and 64constitute a protective layer of box 50.

With reference to FIGS. 4A-6, the protective layer will be referred toin the following description as layer 66 for the sake of clarity, but itwill be understood that any and all of the protective layers 66, 68through to 466 includes one or more protective materials that impartimproved protective properties to the storage box. Protective layer 66may be one of a planar or corrugated sheet of cardboard that isimpregnated with the protective material. Alternatively, protectivelayer 66 may comprise a film that is bonded onto a planar sheet ofcardboard. Furthermore, protective layer 66 may constitute a separatethin film. Finally, protective layer 66 may constitute a powder orliquid coating that is sprayed or otherwise deposited onto one of thesheets in the box.

The protective layer 66 may constitute cardboard that is impregnatedwith a chemical that renders that layer water impervious or waterrepellant. The chemical may render the layer fire resistant or fireretardant. The chemical may be a fungicide that prevents mold fromgrowing, or a pesticide that kills insects such as silverfish or thatrepels such insects because of an odor or taste associated therewith. Awide variety of chemicals are known to produce these properties, buthave not been previously applied to corrugated cardboard or have notbeen applied in combination with each other to cardboard. So, forinstance, a wide variety of chemicals and chemical components may beused for these purposes. These include, but are not limited to, a wax,or an oil may be impregnated into the layer, or a plastic film may beused to create a water repellant or resistant layer. Chemicals such asaluminum hydroxide and diammonium phosphate, polybrominated diphenylether, polybrominated biphenyl or brominated cyclohydrocarbons can besprayed or otherwise applied to a one of the layers 60, 62 or a separatecardboard sheet in order to create a fire retardant layer. Boric acid orhydrogen peroxide may be used in layer 66 to act as a pesticide orfungicide. So, for example, in FIG. 4, one or more of sheets 60, 62 and64 may be impregnated with a suitable insecticide to repel insects suchas silverfish from box 50. Or, in FIG. 4A, layer 166 of a suitablefire-retardant chemical may be applied over the outer sheet 162 of thebox. Or, in FIG. 4B, a fungicide may be applied as layer 268 over theinterior sheet 260 of the box. Or, in FIG. 4C, layer 366 may be asuitable water repellant and layer 368 may be a fire retardant. Or, inFIG. 5, a fire-retardant layer 466 may be sandwiched between two sheets462, 470 of cardboard.

It will be understood by those skilled in the art that one or more orall of these and other chemical compounds may be applied to thecardboard in one or more layers in order to protect the box from one ormore of water, fire, insects and mold. Furthermore, any other chemicalor substance may be applied to the interior or exterior of box 50, ormay be impregnated into the cardboard layers thereof in order to givethe materials thereof the protective qualities that are desired.

FIGS. 7-9 illustrate a mailing envelope in accordance with the presentinvention and being generally indicated at 700. Envelope 700 comprises apouch 702 and a flap 704. Flap 704 includes an adhesive layer 706 overwhich a protective paper cover (not shown) is applied. The paper coveris removed from layer 706 when the envelope 700 has been stuffed and isto be closed. Flap 704 is folded over into abutting contact with wall710 and adhesive layer 706 secures flap 704 to wall 710. Preferably,both the pouch 702 and flap 704 incorporate protective materialstherein. The protective materials are applied therein to secure theenvelope 700 against threats such as fire, water, insects, mold, fungi,bacteria and theft.

In accordance with one of the specific features of the presentinvention, walls 710 and 712 are manufactured from a plurality oflayers. One or more of those layers include materials that impartprotective properties to envelope 700. Walls 710 and 719 may beintegrally formed or may be secured together in some suitable manner.Walls 710 and 712 surround and define an interior cavity 714 into whichthe articles to be mailed are placed.

FIG. 8 shows a first embodiment of the structure of wall 710. Wall 710comprises a first layer 716, a second layer 718 and a third layer 720.First layer 716 may be manufactured from any material, such as a paperor cardboard product. Second layer 718 is applied onto a first surfaceof first layer 716. Second layer 718 is manufactured from a plasticblister-type material and is thus waterproof. Second layer 718additionally provides cushioning for the articles retained within thecavity 714. Third layer 720 is applied to a second surface of firstlayer 716. Third layer 720 is provided to protect first layer 716 from adifferent threat to that of second layer 718. So, for instance, thirdlayer 720 may include a fungicide or a fire-retardant material. Aspreviously described in relation to the storage box, if first layer 716is a paper product, a protective material may be impregnated directlyinto that layer. Second and third layers 718, 720 may be applied as afilm or sprayed onto first layer 716. The structure of wall 710 is shownby way of illustration only. Any suitable layering of differentmaterials may be utilized to protect the articles within pouch 702 froma variety of different threats such as water damage, fire damage, mold,bacteria, fungi, insects and theft.

FIG. 8A shows a second embodiment of a possible structure of theenvelope wall, said wall being generally indicated at 810. Wall 810again is made up from a first layer 816, a second waterproofblister-type layer 818 and a third layer 820. In this instance, thirdlayer 820 is applied onto second layer 818 instead of onto the firstlayer 816. Third layer 820 may include a fire-retardant that protectsthe blister type second layer 818 from melting.

FIG. 8B shows a third embodiment of the possible structure of theenvelope wall, being generally indicated at 910. Again, wall 910comprises a first layer 916, a plastic blister-type material secondlayer 918 applied to a first surface of first layer 916, a third layer920 applied to a second surface of first layer 916, and a fourth layer922 applied to a second surface of the second layer 918. Again, each oneof the first, second, third and fourth layers 916-922 providesprotection against a different threat.

Finally, FIG. 9 shows a fourth embodiment of the structure of theenvelope wall being generally indicated at 1110. The structure of wall1110 is substantially identical to that of the first embodiment 710thereof, with the exception that the wall includes a pouch 1112 thatsurrounds and retains an RFID tag 1114 therein to protect envelope 700from the threat of theft.

As with the storage box, the protective layers in envelope 700 may beimpregnated into the material of the layer, applied as a film, appliedas a spray coating or may be sandwiched between the various layerswithin envelope 700.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the invention are anexample and the invention is not limited to the exact details shown ordescribed.

1. A packaging article for protectively storing and shipping perishablepaper products, wherein said packaging article comprises: a bottom wall;a plurality of side walls extending upwardly away from the bottom wallto surround and define an interior cavity; said cavity being adapted toretain the paper products therein; a closure receivable over an upperend of the side walls to close off said interior cavity; a protectivematerial applied to one or more of said bottom wall, side walls andclosure to protect the same from one or more threats selected from thegroup consisting of fire, water, insects, mold, fungi, bacteria andtheft.
 2. The packaging article as defined in claim 1 wherein theprotective material is applied as a film over the one or more of saidbottom wall, side walls and lid.
 3. The packaging article as defined inclaim 1, in which the protective material is sprayed over the one ormore of said bottom wall, side walls and lid.
 4. The packaging articleas defined in claim 1, in which the protective material is sandwichedwithin the one or more of said bottom wall, side walls and lid.
 5. Thepackaging article as defined in claim 1, in which the protectivematerial is one or more of a wax, an oil, a plastic, aluminum hydroxide,diammonium phosphate, polybrominated diphenyl ether, polybrominatedbiphenyl, brominated cyclohydrocarbons, boric acid hydrogen peroxide anda radio frequency identification tag.
 6. The packaging article asdefined in claim 1, wherein each of the bottom wall, side walls andclosure of the box includes at least: a first planar layer; a secondlayer; said second layer being one of corrugated and blistered; and athird planar layer; said third planar layer being applied to one of thefirst and second layers; and wherein the protective material is appliedto one or more of the first, second and third layers.
 7. The packagingarticle as defined in claim 6, wherein the protective material isimpregnated into one or more of the first, second and third layers. 8.The packaging article as defined in claim 6, wherein the protectivematerial is applied as a film over one or both of the first and thirdlayers.
 9. The packaging article as defined in claim 6, wherein theprotective material is sprayed over one or both of the first and thirdlayers.
 10. The packaging articles defined in claim 9, wherein theprotective layer is sprayed in one of a powder form and a liquid formover the one or both of the first and third layers.
 11. The packagingarticle as defined in claim 6, wherein the protective material issandwiched between an adjacent two of the first, second and thirdlayers.
 12. The packaging article is defined in claim 6, wherein theprotective material comprises: a first component that protects thepackaged article against a first threat.
 13. The packaging article asdefined in claim 12, wherein the first threat is one of water damage,fire damage, mold, insects, bacteria, fungi and theft.
 14. The packagingarticle as defined in claim 12, wherein the protective material furthercomprises: a second component that protects the box against a secondthreat.
 15. The packaging article as defined in claim 14, wherein thesecond threat is a different one of water damage, fire damage, mold,insects, bacteria, fungi and theft.
 16. The packaging article as definedin claim 14, wherein the protective material further comprises: a thirdcomponent that protects the box against a third threat.
 17. Thepackaging article as defined in claim 16, wherein the third threat is afurther different one of water damage, fire damage, mold, insects,bacteria, fungi and theft.
 18. The packaging article as defined in claim16, wherein the protective material further comprises: a fourthcomponent that protects the box against a fourth threat.
 19. Thepackaging article as defined claim 18, wherein the fourth threat is thelast different one of water damage, fire damage, mold, insects,bacteria, fungi and theft.
 20. The packaging article as defined in claim18, wherein each of the first, second, third and fourth components areselected from the group consisting of a wax, an oil, a plastic, aluminumhydroxide, diammonium phosphate, polybrominated diphenyl ether,polybrominated biphenyl, brominated cyclohydrocarbons, boric acid,hydrogen peroxide and a radio frequency identification tag.